Hey Yall! My kit was made by Gibson Precision Exhaust, other kits should be similar though. To begin; safety first. Always use wheel chocks and when raised use jackstands, wear safety glasses with power tools, and use hand tools for their designed purpose.
Tools needed: WD40, 15MM Socket, 13MM socket, 9/16" socket, 15MM wrench, hacksaw, power drill, 3/8" drill bit.
Install time: 2.5-3.5 hours Step 1:
Layout your parts on the floor as it will be under your truck with all clamps, hangers, etc. To confirm you have all necessary parts: Step 2:
Remove factory Headpipe.
It is held on by two 15MM bolts that look like this:
Be your own best friend and use plenty of WD40 on these as you will be reusing the headpipe clamping bolts with your new headpipe. Step 3:
Remove muffler from hanger.
The large tips on the ends can be difficult to get started through the small hole in the rubber piece, the good news is, this isn't your average everyday rubber so you can be firm with it. The easy way is to spray in some WD40 for lubrication then take a screwdriver and insert it through the hole and pry the tip through as so:
After the tip of the second side is started through the hole in the rubber piece, be ready to catch the 35 pound factory exhaust as it comes free. Step 4:
Remove factory tailpipe hanger.
Use the same method as the muffler hanger, when the tailpipe is clear be careful not to drop it on the brake lines. Step 5:
Cut tailpipe and take out stock exhaust
I cut mine with a grinder with a cutoff wheel, a hacksaw with suffice though. If using power tools wear safety glasses and be careful to direct sparks away from the fuel tank.
In this project, installation is significantly easier than removal. Step 6:
Install new headpipe.
Slip new flange over new headpipe and install with factory 15MM clamp bolts. Do not fully tighten clamp bolts yet. Step 7:
Install new muffler hanger.
The new hanger that is supplied goes into the same rubber peice the factory exhaust used, a much better design uses bends on the end instead of exploded tips. Step 8:
Install new muffler.
Use hanger for support, install exhaust clamps, but do not fully tighten yet. Step 9:
Remove old tailpipe hanger.
There is one bolt on the inside of the frame rail holding on the factory tailpipe hanger assembly. Step 10:
Install new tailpipes over rear axle.
Install all tail pipe pieces, including tips. Place clamps but do not tighten yet. Step 11:
Align the tips with proper location and spacing and support them to hold the correct finished position. I propped them up with cardboard boxes. Step 12:
Install new tailpipe hangers.
You may have to cut off some of the hanger if they are too long, the hangers are made for general use with many different kits. You may also need to drill a 3/8" hole in the frame if one doesn't exist. In my install I used the bolt hole for the factory tailpipe hanger on the pasenger side and drilled a hole on the driver's side.
The hangers are designed to be mounted on the outside frame rail. and hold the pipe by clamping underneath the exhaust clamp. Step 13:
Assure proper clearances.
Use zip ties if necessary to make sure no brake lines, fuel lines, parking brake cable, or wires are within 2" of the exhaust pipes. Step 14:
Tighten all bolts.
Tighten headpipe flange clamp bolts, all exhaust clamps, hanger bolts, and tips clamps.
Some finished Pictures and a video if you want to hear the Gibson system: